Wind Turbine Gearbox Meshing Angle Tracking Without Internal Sensors
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Solution Overview
Problem
Existing methods for tracking gear tooth meshing angle in wind turbine gearboxes require cumbersome and technically challenging measurements inside the gearbox, which is undesirable.
Innovation Solution
A method for tracking the gear tooth meshing angle using a virtual angle estimation based on monitored shaft positions and gearbox topology, with periodic resets to maintain accuracy, allowing for the generation of a torque modulation signal to mitigate noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If measurements are taken inside the gearbox to track gear tooth meshing angle, then measurement precision is improved, but device complexity and ease of operation deteriorate due to cumbersome and technically challenging interior measurements
Solution Approach 1:
The patent uses shaft position sensors as intermediary measurement devices that indirectly track the gear tooth meshing angle through mathematical relationships based on gearbox topology, avoiding the need for direct interior gearbox measurements. This mediator approach maintains measurement precision while eliminating the complexity of interior measurement systems
Solution Approach 2:
The patent replaces direct mechanical measurement systems inside the gearbox with an electronic/mathematical calculation system that uses shaft position data and gearbox topology information to compute the meshing angle, thereby reducing device complexity while maintaining measurement accuracy
2Ease of operation
If virtual gear tooth meshing angle tracking is implemented without interior measurements, then ease of operation is improved, but measurement precision may deteriorate due to virtual estimation rather than direct measurement
Solution Approach 1:
The patent implements periodic resetting of the virtual meshing angle based on feedback from actual shaft position measurements, ensuring that the virtual tracking remains synchronized with the actual gear meshing state. This feedback mechanism maintains measurement precision while preserving the operational simplicity of the virtual angle approach
Solution Approach 2:
The patent pre-calculates and stores gearbox topology information and meshing angle relationships during the design phase, enabling accurate real-time tracking during operation without requiring complex real-time computations. This preliminary preparation ensures precision while maintaining ease of operation during actual use
Data Source
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AI summary
A method for tracking a gear tooth meshing angle of a gearbox (3) of a wind turbine is disclosed. An initial reference virtual gear tooth meshing angle of the gearbox (3) is selected, and an angular position of a high speed shaft (6) and/or a low speed shaft (4) of the gearbox (3) is monitored. A virtual gear tooth meshing angle relative to the reference virtual gear tooth meshing angle is estimated, based on the monitored angular position of the high speed shaft (6) and/or the low speed shaft (4) and on information regarding topology of the gearbox (3). A number of full rotations of the high speed shaft (6) and/or the low speed shaft (4) which corresponds to an integer number of full periods of gear meshing of the gearbox (3) is calculated, and the reference virtual gear tooth meshing angle is reset each time the high speed shaft (6) and/or the low speed shaft (4) has performed the calculated number of full rotations. The estimated virtual gear tooth meshing angle is applied to a periodic noise signal of the wind turbine.